CPU-95

Advanced Digital Ignition System

For Industrial Engines
Features
Comprehensive Display Capability
„„ Two-line, alphanumeric, backlit dis-
play indicates the following operating
parameters:
„„ System status and mode
„„ Ignition energy level, mode and num-
ber of strikes
„„ Global timing (in degrees BTDC)
„„ Individual cylinder timing
„„ Value of timing control signal
(4-20mA)
„„ Relative spark plug voltage indication
by cylinder
„„ Engine speed (in RPM)
„„ Engine overspeed setpoint
„„ Diagnostic messages
Spark Characteristic Control
For improved engine performance and
combustion stability, ignition of lean mix-
tures for emissions reduction or improved
starting and loading characteristics:
„„ Double-striking mode
(selectable ON/OFF)
„„ VariSpark™ mode
(selectable ON/OFF, VariSpark™
model only)
„„ Manual or automatic ignition energy
level control (3 levels)
Ignition Timing Control Modes
Local and remote control of ignition ti-
ming (global or individual cylinder) allows
engine starting and running performance
to be optimized.
„„ One-step timing change vs. input
signal or RPM
„„ Keypad control via display module
„„ Terminal program control via serial port
„„ Analog 4 to 20mA control
„„ Timing control vs. RPM
Serial Communications to PC or
Engine Management System
All system features, display data, and
configuration inputs are accessible via an
integral RS-485 serial port. A dual port
display module enables simultaneous use
of both the system display, and a supervi-
sory control system utilizing ModBus RTU.
System Configuration
Engine-specific configuration parame-
ters are contained in a plug-in memory
(EEPROM) which can be moved to a
spare unit if necessary. The memory can
be configured in the shop or on location
using a personal computer connected to
the serial port.
„„ Engine firing pattern
„„ Number of gear teeth or flywheel holes
sensed
„„ Timing control vs. 4-20mA and RPM
Diagnostics, Testing, Shutdown
Capabilities
Advanced and patented diagnostics, self-
test, and alarm/shutdown capabilities are
included with each CPU-95 system:
„„ Primary and secondary discharge
faults identified as to cylinder
„„ Status of system pickups
„„ Verification of number of teeth/holes
„„ Test firing of selected cylinder(s)
(optional)
„„ Overspeed condition
„„ Alarm and shutdown outputs
Retrofit Existing Altronic III, III-CPU,
CPU-90 Systems
Retaining many system components ma-
kes conversion to the CPU-95 simple and
cost-effective.
Display Options
The Ignition Module operates in con-
junction with a variety of display/control
options through its integral RS-485
communication port. This facilitates the
application of CPU-95 systems to gas
engines operating at varying stages of
automation and sophistication.
Terminal Program
The CPU-95 Terminal Programs can be
operated via the Ignition Module’s serial
port or through the second serial port
located on the enhanced CPU-95 Display
Module. This Windows™-based software
package duplicates the display and control
capabilities of the Display Module on
a compatible Personal Computer. The
Terminal Program also enables a user to
reconfigure the engine specific data (firing
pattern, number of holes or teeth, and
timing control curves) in the field, as well
as to simultaneously monitor all primary
and secondary discharge diagnostics for
each engine power cylinder.
Overview
„„ Microprocessor-based, crankshaft–re-
ferenced digital ignition system for
medium-sized natural gas-fueled
engines
„„ Optimizes engine combustion and
performance, as well as fuel efficiency
and spark plug service life
„„ Delivers full-time system, primary
discharge, and secondarydischarge
diagnostics (patented)
„„ Enhanced, user-friendly Display
Module insures a convenient means
of adjusting system settings and
access to critical ignition operating
information, including all diagnostic
messages along with data logs, USB
connectivity, and the ability to upload
the ignition programming code to the
CPU-95 Ignition Module
„„ Special CPU-95 variants for SI contro-
ller-equipped Caterpillar 3500 engines
and for low BMEP, slow speed integral
compressor engines (VariSpark™)
„„ Simple and cost-effective retrofit
option for CPU-90, III-CPU, and even
Altronic III operators
„„ Class I, Division 2, Group C and D
certified by the Canadian tored for operation within preset limits.
Standards Association (CSA)
The Altronic CPU-95 is a 24 Vdc-
powered, microprocessor-based digital
ignition system designed for application
to medium-range industrial gas engines.
Advantages include a full-featured user
display and interface, spark characteri-
stic control, advanced timing adjustment
options, serial communications, and
state-of-the-art diagnostics.
Full access to all CPU-95 operating data
and control functionality is available
through an advanced, user-friendly Dis-
play Module as well as via a PC operating
the provided CPU-95 Terminal Program.
Both options display essential engine and
ignition data such as RPM, timing angle,
spark energy level, and diagnostic messa-
ges, along with global and individual cylin-
der timing adjustments, spark energy level
control, overspeed setpoint and double
strike/extended spark (VariSpark™ variant)
selectability. Additionally, the Enhanced
Display Module features extensive spark
reference number graphing and trending.
Patented CPU-95 diagnostics and pro-
gnostics (predictive diagnostics) supervise
all ignition system-related functions. The
secondary analysis capabilities detect
shorted spark plugs and leads, as well
as spark plugs that exhibit high voltage
demand or are not firing at all. A display
of the relative voltage demand of each
spark plug is provided, allowing spark plug
changes to be predicted and scheduled.
Module and pickup operation, timing input,
and primary output functions are also moni-
The CPU-95 system is shop or field
configurable. Using the standard Termi-
nal Program and the Enhanced CPU-95
Display Module, the user has the added
flexibility and convenience associated
with a USB-based connection to the
system for programming. Operation
of the Enhanced Display Module also
enables the user to download and retain
the ignition operating parameters (firing
code, number of monitored gear teeth,
4-20mA or RPM control loop, etc.) from
the connected Ignition Module. Should
the ignition module ever require replace-
ment, the Enhanced Display Module can
then simply upload the correct ignition
operating parameters into the new unit
without need for a laptop, the Terminal
Program, or the services of an instrumen-
tation technician.
Components
Each CPU-95 system is composed of the
Ignition Module, two magnetic pickups
and cables, a primary wiring harness,
and an ignition coil for each spark plug.
A system Display Module, typically used
(but not required), is also available. A
Hall-effect pickup and cable, as well as
a magnet turning at camshaft-speed are
utilized on 4-cycle applications only.
Operation
The diagram above illustrates how these
components are integrated into an ope-
rating system. To insure that the spark is
delivered at precisely the right moment
for each engine cylinder on each revolu-
tion, the CPU-95 determines the position
of the engine crankshaft through the use
of a magnetic pickup sensing starting
ring gear teeth or holes drilled into the
flywheel allowing precise determination
of crankshaft angular position in real
time. Matching that to a pre-programmed
system memory, the CPU-95 system can
achieve extremely high ignition timing
accuracy. A second, flywheel-based ma-
gnetic pickup, is used to generate a once
per crankshaft revolution reset pulse.
Four-cycle applications also utilize a Hall-
effect pickup sensing a magnet turning at
camshaft speed to determine the com-
pression cycle of the engine.
The CPU-95 Ignition Module is typical-
ly mounted on or near the engine. This
24-VDC-powered module accepts and
processes the input data derived from the
engine-based pickups and any control
data being brought into the system
through the CPU-95 Display Module,
Terminal Program, or engine management
system (see review to left). This control
information, including timing adjust-
ments, spark energy control, and multi-
strike or extended duration (VariSpark™)
directly influences both the moment
at which the spark is delivered and the
important characteristics of that spark. A
4-20mA timing control input from a su-
DISPLAY MODULE
4-20mA TIMING
CONTROL INPUT
USB (ENHANCED
DISPLAY ONLY)
RS-485
MODBUS
RTU
(ENHANCED DISPLAY ONLY)
pervisory control system or an instrument
monitoring a specific operating parameter
(such as fuel manifold pressure or air
manifold temperature) is also available
as an additional means of optimizing
performance.
Diagnostics
To assist operators of gas engines in pro-
perly locating and diagnosing the source
of ignition-related problems, a suite of
comprehensive, easy-to-use, troubleshoo-
ting diagnostics have been developed and
imbedded into the CPU-95 system. The
goal of these diagnostics is simple: redu-
ce engine downtime and all of the costs
associated with it.
CPU-95 diagnostics are split into two
separate groups. System diagnostics
IGNITION MODULE
RS-485
24 VDC
PICKUP
POWER
SIGNALS
IGNITION
OUTPUTS
(UP TO 20)
are those that relate primarily to the
operation of the ignition system itself or
to the inputs into the system (pickups,
control inputs, etc.). The second group
encompasses Altronic’s patented prima-
ry and secondary discharge diagnostics
(U.S. Patent No. 5,623,209). These
powerful, non-intrusive diagnostics are
unique in the industry for their reliability
and the fact that they do not require a
special ignition coil, any add-on probes or
clamps, or any other special equipment.
Instead, Altronic primary and secondary
diagnostics utilize standard ignition coils
(typically the same ignition coil that is on
the engine during a retrofit) in assessing
secondary voltage demand. This valuable
capability assists users in determining
the proper point at which to change their
spark plugs, in troubleshooting problema-
tic primary and secondary connections,
and in detecting combustion anomalies
in the cylinder (such as air/fuel ratio or
imbalance conditions). The secondary
diagnostic functions also assist the user
selecting the appropriate point at which
to manually or automatically adjust the
delivered spark energy (there are three
levels available) to assure maximum spark
plug life and reliable combustion.

HALL-EFFECT
CYCLE SENSOR
(4-CYCLE ONLY)

CAMSHAFT-
MOUNTED IGNITION COILS
MAGNET
(4-CYCLE ONLY)
OPTIONAL PC OR
SCADA SYSTEM FOR 1R 2R 3R
REMOTE MONITORING
AND CONTROL
MAGNETIC
PICKUPS
ENGINE
(1 TO 18 CYLINDERS)

1L 2L 3L
Enhanced Display Module
For users seeking an expanded level of
capability or intending on integrating
their CPU-95 system into an existing or
planned supervisory control or remote
monitoring system, Altronic offers its
Enhanced Display Module (791909-1).
In addition to incorporating a Modbus
RTU-enabled serial port for communi-
cation with a remote monitoring system
or local controller, the Enhanced CPU-
95 Display Module also supports USB
connectivity to a PC and the associated
CPU-95 Terminal Program. An innovative
ignition memory “cloning” system allows
this advanced Module to upload the
ignition system configuration file (number
of cylinders, firing pattern, number of
monitored gear teeth, 4-20mA or RPM
curve, etc.) from a connected Ignition
Module, retain it indefinitely in its own
memory, and - without need of a laptop -
to download that memory information to a
User can monitor spark refer-
ence numbers individually and
simultaneously.
new Ignition Module in the event that the
existing module is damaged or requires
replacement.
The larger system display allows for the
simultaneous display of large amounts of
information, and the ability to “map” the
CPU-95 Ignition Outputs to the appro-
priate cylinder designation. Thus, the
user retains indication of the appropriate
CPU-95 output (A, B, C, etc.) while also
getting diagnostic indications in terms
of the on-engine cylinder reference (5L,
3R, #6, etc.). Advanced spark reference
number graphing is also made possible
by the incorporation of the larger display
(see sample displays above). “Live”
and data log-based XY graphing of the
monitored Spark Reference Number for
a given cylinder and “at-a-glance” indi-
cation of the relative value of the Spark
Reference Number across all cylinders
gives the user unparalleled access and
convenience in ignition system trouble-
shooting and monitoring.
Added capabilities also include an on-
board data logging function which retains
up to one-hundred (100) date and time-
stamped records of the Spark Reference
Number for each output which have been
recorded at user-adjustable intervals.
These records are stored in a rolling “first
in-first out” fashion and are accessible
for download via the Enhanced Display
Module for offline trending and analysis.
„„ Larger display for greater single-screen
access to operating, diagnostic, and
setup data
„„ Features an integral graphing and
data-logging capability for convenient
spark reference number analysis
„„ Allows for display mapping of indivi-
dual outputs (Output A = Cylinder 1L,
Output B = Cylinder 1 R, etc.)
„„ Incorporates a unique upload-
download capability to assist users
in configuring a new or replacement
CPU-95 Ignition Module without need
of a laptop
„„ On-board USB connectivity and a
Modbus RTU-capable serial port are
included for simple connection to a
PC for continuous monitoring and/or
automation system integration
„„ Password protection of key operating
characteristics including overspeed
setpoint, spark configuration, and
diagnostic thresholds
Specifications Dimensions
Input Signals:
Magnetic pickups, (1) ring gear teeth or drilled holes Display Module
6.50
(1) reset (1/engine revolution)
Hall-effect for compression stroke reference (4-cycle only)
Control Inputs: Shutdown
Ground to activate Feature control (timing, energy, double-strike, VariSpark™)
Timing Control Manual (display module keypad) 6.50

Inputs: Analog (4-20mA control signal)

Digital (RS-485 serial data)
Output:
47kV maximum output voltage
300–600 µs duration (791950/952/955) 6.00
1.25
1000–2000 µs duration with VariSpark™ option (791958) 2.19

Control Outputs: Normal fire confirm

Solid State, NC switches Alarm fault
Shutdown fault
Communications: RS-485 serial 6.00 5.50

USB, Modbus RTU (Enhanced Display Only)

Display: Alphanumeric, backlit
Power Rqmt: 24VDC, 1–8 amps typ. (varies by application) .203 DIA.
NOTE: On many applications, power can be supplied by engine-driven 5.50 (TYP 4)
Altronic 24 Vdc alternator; see form ALT.
Ignition Module

Temperature: -40°F to +158°F (-40°C to +70°C) 9.90

6.00

Ordering Information
CPU-95 Ignition Module – 1 per system
791950-8 Ignition Module, 8 outputs, standard
791950-16 Ignition Module, 16 outputs, standard 8.75 9.75

791950-18 Ignition Module, 18 outputs, standard

791952-18 Ignition Module, 18 outputs, dual capacitor
791955-16 Ignition Module, 16 outputs, Caterpillar G3500 low emissions engines
791958-16 Ignition Module, 16 outputs, VariSpark™ extended spark duration
6.25

CPU-95 Display Module – 1 per system

USE WITH IGNITION MODULE
791950-xx
791952-18
PART NO. DESCRIPTION 791958-16 791955-16
791902-1 Display Module, standard X
791902-1S Display Module, no test X
791902-2 Display Module, Cat G3500 X
791908-1 Display Module, dual port* X
791909-1 Display Module, enhanced X
*Not recommended for new installations.

712 Trumbull Avenue / Girard, Ohio 44420 USA

P: 330-545-9768
F: 330-545-3231
www.altronic-llc.com

Form CPU-95 5-12 ©2012 Altronic. LLC